Embroidered Beach Hat

This Beach Hat is the perfect accessory for your day in the summer sun!

Look great and protect your eyes and face while at the beach, in the garden, running errands, out for a walk, or every time you want to look great!

Sunny designs and darling buttons make this cute hat fashionable to wear all summer long!

The finished size for this project varies according to individual measurements.

Supplies & Materials:

Supplies needed:

1/4 yard light-colored twill or denim
1/2 yard denim fabric
1/4 yard terry trim
Medium weight cut-away stabilizer
Air-erase pen
Temporary spray adhesive
One 14x18 inch sheet of double-sided, stiff, fusible interfacing
Buttons (optional)

The designs used in this tutorial include:

Sunshine - Small also available in Large

Palm Tree - Small also available in Large

Flip-Flops with Polka Dots - Small also available in Large

Determining Hat Size:

Measure the circumference around the head above the eyebrows and ears. Find the hat size below and refer to it while following the project instructions.

The large size will work for 23 1/2 inches, the medium size will work for 22 1/2 inches, and the small size will work for 21 1/2 inches.

Gather Materials:

Click here to download the hat pattern. The pattern is split in five pieces and will print on five pieces of paper.

Printed pattern pieces for a beach hat laid out on a wooden surface. The paper sheets include labeled sections with curved lines and tabs for assembly.

The brim section of the pattern has four sections. Cut around the straight edges of the pattern and tape them together.

Set the patterns aside for now.

Printed paper pattern for an embroidered beach hat with labeled sections LT, RT, LB, RB arranged around a central circle, held by a hand on white surface.

Create full-size paper templates of the designs. Cut the designs down to size to make them manageable.

Measure and mark the side piece on the light twill fabric, based on the size of the hat:

Large = 26 3/4 x 5 1/2 inches

Medium = 25 3/4 x 5 1/2 inches

Small = 24 1/2 x 5 1/2 inches

Find the center of the rectangle by measuring the ends and dividing by two. Make marks on the ends, and then draw a line across the fabric connecting the marks. This line will be used for placing the designs.

Mark the center by measuring the line and dividing by two. Poke a hole in the center of the first design and align it with the center mark. Place the other two designs on the line about 3 1/2 inches from the center design (from edge to edge). Mark the vertical axis points of all the designs onto the fabric.

Hand tracing black-and-white flower stencil designs onto a fabric strip with a pencil on a wooden table, three stencils spaced in a row.

Remove the templates and draw lines connecting the vertical axis marks. These lines will be used for hooping.

Hand holding pen draws lines and dots on white fabric with a 12-inch black ruler on a wooden table, blue fabric background.

Start Embroidering:

Lightly spray the fabric with temporary adhesive. Hoop the fabric and stabilizer together for the first design, aligning the lines on the hoop with the lines on the fabric. Align the needle directly over the center point on the fabric, and embroider the first design.

Repeat hooping and embroidering the two other designs.

Brother sewing machine embroidering a colorful sun design on white fabric held in an embroidery hoop under the needle.

Once the designs are embroidered, carefully cut away the excess stabilizer.

Hand cutting white fabric with blue and pink sunflower embroidery using black-handled scissors on a light-colored surface.

Cut out the shape of the side piece.

Hand holding black scissors cutting fabric with two embroidered designs: a green palm tree with multicolored trunk and a sunflower with yellow petals and red center on white background.

Cut two pieces of the brim fabric. Place the brim pattern on one piece of the denim fabric, pin in place, and cut the pattern, including the notches, and then...

Printed circular paper pattern with labeled sections and tabs, placed on dark fabric, being cut with scissors by a hand.

...cut out the hole in the center.

Cut along the outer line for the large size, cut along the middle line for the medium size, and cut along the inner line for the smallest size.

Cut 1/4 inch long slits along the inner edge at about every inch.

Remove the pins and use the same pattern to cut out the other piece of denim fabric.

Hand cutting gray fabric with scissors along a paper pattern for a circular piece labeled with sections and sewing instructions on a brown wooden table.

Remove the pins from the second piece of denim fabric.

Trim the pattern to use for the interfacing. Cut 1/8 inch in from the outer edge and 5/8 inch in from the inner circle.

Hand cutting a white paper pattern with labeled sections RT, LT, LB, RB on a wooden surface, likely for a hat project.

Lay the pattern on the interfacing, pin in place, and cut out the pattern.

Hands cutting white fabric placed under a segmented paper pattern labeled with sewing instructions for sections RT and RB on a dark wooden surface.

Lay the two pieces of denim, right sides together, and pin in place.

Hand holding folded blue fabric layered under pinned light gray fabric with a circular cutout on a wooden table, likely in sewing process.

Sew a 1/2 inch seam around the outer edge only.

Close-up of a sewing machine stitching light blue denim fabric with a white pin holding the material in place, illuminated by the machine's integrated light.

Turn the fabric right side out and press the seams.

Close-up of a navy blue fabric piece with a circular cutout being pressed with a steam iron on an ironing board.

Add the interfacing between the two layers of denim fabric.

Close-up image showing a hand holding a blue fabric hat with the inner edge turned upward, revealing a white lining and black striped binding inside.

Press the brim on both sides to activate the fusible interfacing.

Iron pressing a round piece of dark blue fabric with hand-stitched running stitches around the inner circle on a white ironing board cover.

Sew a 1/8 inch seam along the outer edge of the brim. Sew four more seams every 1/4 inch towards the center creating concentric circle seams.

Close-up of sewing machine stitching dark blue denim fabric with a curved edge, illuminated by the machine's built-in light, on a white surface.

Pin the top section pattern to the light-colored fabric and cut out the shape, including the notches. Take out the pins and reuse the pattern to cut out another piece of the same fabric with the same pattern.

Printed paper pattern labeled "Hat Top" pinned to white fabric with layered beige fabric beneath. Black-handled scissors lie nearby on dark wood surface.

Lay the pieces wrong side together and sew a 1/2 inch seam along the outside edge of the fabric.

Close-up of a sewing machine needle and presser foot stitching white fabric, with focused light illuminating the work area on a light-colored surface.

Cut a piece of terry cloth the same size as the size of your embroidered side fabric.

Large = 26 3/4 x 5 1/2 inches

Medium = 25 3/4 x 5 1/2 inches

Small = 24 1/2 x 5 1/2 inches

Fold over the long sides 1/4 inch and press in place.

Close-up of a light blue terry cloth fabric strip being pressed with the tip of a steam iron on a white ironing board cover.

Fold the long sides of the embroidered fabric together over to the wrong side 1/2 inch and press in place.

Close-up of fabric panels with embroidered floral designs being ironed on an ironing board, featuring a palm tree and a sunflower pattern.

Sew a 1/4 inch seam along the long sides of the fabric and then the terry cloth lining.

Close-up of a sewing machine stitching a black outline of a flower with a pink center on white fabric. The presser foot and needle are visible.

Lay the embroidered side fabric with the terry cloth liner wrong sides together.

Insert 1/2 inch of the top sections allowance between the embroidered fabric and the terry cloth liner. Pin in place.

Be sure to align the top section with a narrow side of the oval facing the side pieces.

Pieces of fabric laid out on a wooden table, including a white circular piece, a white strip with embroidered palm tree, sun, and flip-flop designs, and light blue fabric underneath. A hand is lifting the fabric strip.

Sew a 1/4 inch seam along the top edge of the side piece, inserting the allowance of the top section in between the side sections as you sew.

Sew the side, top, and lining together, sewing out from the center and stopping about 2 inches from the end of the side pieces. Then sew from the center out on the opposite side, also stopping 2 inches from the end of that side.

Close-up of a sewing machine foot stitching two layers of light beige fabric together with light shining on the sewing area in a dark environment.

Align the bottom ends of the sides together, right sides facing each other. Pin in place.

Close-up of a blue terry cloth beach hat with a colorful sun embroidery on the inside, held by a hand pinning fabric on a wooden table background.

Sew a seam starting 1/2 inch in from the bottom edge and angle the seam up to meet at the top.

Close-up of a sewing machine stitching layers of fabric, including light blue fuzzy material and beige fabric, under bright light.

Trim off the excess fabric leaving about a 1/2 inch allowance.

Scissors cutting light blue terry cloth fabric piece on a wooden table, beige fabric with partial colorful embroidery visible in background.

Align the top portion with the opening in the center of the brim. Insert the allowance of the brim in between the layers of the side section and pin in the front and back only.

Then sew a seam right along the edge of the side section all the way around, inserting the allowance of the brim as you sew.

Close-up of a sewing machine stitching a white fabric piece with green and blue flower embroidery onto dark blue denim fabric, secured with pins.

Get Inspired:

Add buttons for extra pizzazz to complete your new sunny beach hat!